Lincoln Corsair: Body Repairs - Vehicle Specific Information and Tolerance Checks / General Procedures - Body Panel Sectioning

Special Tool(s) / General Equipment

Materials

Repair

  WARNING: Electric vehicles damaged by a crash may have compromised high voltage safety systems and present a potential high voltage electrical shock hazard. Exercise caution and wear appropriate Personal Protective Equipment (PPE) safety gear, including high voltage safety gloves and boots. Remove all metallic jewelry, including watches and rings. Isolate the HV system as directed by the Ford Emergency Response Guide for the vehicle. Failure to follow these instructions may result in serious personal injury or death.

NOTICE: The high-voltage battery in a Battery Electric Vehicle (BEV), Hybrid Electric Vehicle (HEV) or Plug-In Hybrid Electric Vehicle (PHEV) can be affected and damaged by excessively high temperatures. The temperature in some body shop paint booths can exceed 60° C (140° F). Therefore, during refinishing operations, the paint booth temperature must set at or below 60° C (140° F) with a bake time of 45 minutes or less. Temperatures in excess of 60° C (140° F) or bake durations longer than 45 minutes will require the high-voltage battery be removed from the vehicle prior to placing in the paint booth.

NOTICE: Electric Vehicle (EV), Hybrid Electric Vehicle (HEV) and Plug-In Hybrid Electric Vehicle (PHEV) vehicles contain a High Voltage Battery (HVB). Before welding near the HVB, the HVB must be removed to avoid heat damage.

NOTICE: If refinishing cure temperatures exceed 60°C (140°F), the charge port light ring must be removed.

NOTICE: Do not carry out body side sectioning repairs in areas of door hinge, safety restraints or striker anchoring points. Welding within 50 mm (1.96 in) of door hinge or striker locations may compromise structural integrity during a collision.

NOTICE: Sectioning within 50mm of the door hinge portion of the A-pillar, B-pillar or dog leg portion is not approved by Ford Motor Company.

NOTE: Factory welds may be substituted with resistance or metal inert gas (MIG) plug welds. Resistance welds may not be placed directly over original location. They must be placed adjacent to original location and match factory welds in quantity. Metal inert gas (MIG) plug welds must equal factory welds in both location and quantity.

NOTE: Do not begin removal of the vehicle body side until the replacement panel is available for reference.

NOTE: LH side shown, RH side similar.

NOTE: The following illustration is intended as a general guideline for body side and door opening panels (DOP) and is not all inclusive.

1. Available service panels.
   

1. Possible Sectioning Points
   

1. Restore the vehicle dimensionally to pre-damage condition.
   Refer to: Body and Frame (501-26 Body Repairs - Vehicle Specific Information and Tolerance Checks, Description and Operation).
   

1. As a general rule, sectioning cut points should be chosen to result in the smallest repair area possible.
   Refer to: Vehicle Specific Body Construction (501-26 Body Repairs - Vehicle Specific Information and Tolerance Checks, Description and Operation).
   

1. Detrim the vehicle as necessary in the area to be repaired.
   

1. Only remove as much of the outer body side as necessary.
   Use the General Equipment: Air Body Saw
   Use the General Equipment: Spherical Cutter

1. Where possible, create a lap-joint backer plate from an unused portion of the old or replacement panel. This will create a stronger joint.
   Refer to: Joining Techniques (501-25 Body Repairs - General Information, General Procedures).
   Use the General Equipment: MIG/MAG Welding Equipment
   Use the General Equipment: Resistance Spotwelding Equipment
   Use the General Equipment: Locking Pliers

1. Rough finish all sectioning joints with a fibre-based body filler, final finish sectioning joints and plug welds with a conventional body filler.
   

1. Properly seal all joints to prevent moisture intrusion. Water and moisture migrate toward horizontal joints and corrosion tends to occur more rapidly in these areas.
   Material: Seam Sealer / TA-2-B, 3M™ 08308, LORD Fusor® 803DTM

1. NOTICE: The HVTB (High Voltage Traction Battery) in an EV (Electric Vehicle), HEV or PHEV can be affected and damaged by excessively high temperatures. The temperature in some body shop paint booths can exceed 60°C (140°F). Therefore, during refinishing operations, the paint booth temperature must set at or below 60°C (140°F) with a bake time of 45 minutes or less. Temperatures in excess of 60°C (140°F) or bake durations longer than 45 minutes will require the HVTB be removed from the vehicle prior to placing in the paint booth.

   NOTICE: If refinishing cure temperatures exceed 60°C (140°F), the charge port light ring must be removed.

   Proceed with the refinishing process using a Ford approved paint system and manufacturers recommendations.
   

1. Restore corrosion protection.
   Refer to: Corrosion Prevention (501-25 Body Repairs - General Information, General Procedures).
   

1. Reinstall vehicle trim as necessary.